Wearables Leverage Smart Technologies to Improve Safety and Productivity
Long, long ago, in a land that time has forgotten, there used to live human beings who were not connected to the Internet 24/7. They did not carry a telephone, camera, calculator, newspaper, encyclopedia, radio, calendar, clock, map, photo album, and book simultaneously on their persons.
What a dumb world they lived in! Does that sound harsh? Maybe, but what else would you call the opposite of the “smart” world we live in today? The example above seems silly, but 30 years ago the thought of having access to all those things — and more! — in the palm of your hand would’ve seemed just as crazy.
Today, smart technology is everywhere you look. It’s in our smartphones and other electronic gadgets. It’s in our homes and schools. We’re even wearing smart technology these days. From smart watches to fitness trackers, “wearables” are more popular than ever.
While many of the first uses of smart technologies in wearables focused on improving personal physical fitness, clever developers have created new devices for the workplace. If your workplace doesn’t already use some form of wearables for employees, it likely could in the near future.
In this article, we’ll take a closer look at the important role wearables are playing in today’s advanced manufacturing and logistics workplaces. Read on to learn how smart technologies are making employees safer and workplaces more productive and efficient.
What are Wearables?
According to Investopedia:
“Wearable technology, also known as ‘wearables,’ is a category of electronic devices that can be worn as accessories, embedded in clothing, implanted in the user’s body, or even tattooed on the skin. The devices are hands-free gadgets with practical uses, powered by microprocessors and enhanced with the ability to send and receive data via the Internet.”
When you hear the word “wearables,” smart watches and fitness trackers you wear around your wrist are probably the first devices that come to mind. However, as the definition above reveals, developers are becoming more and more creative when it comes to wearable technology.
Having access to your smartphone features on your watch and keeping track of the number of steps you’ve taken both have obvious benefits. But what about in the workplace? Is there really a need for these types of devices on the job?
After all, aren’t robots taking over anyway? Will there even be factory jobs for people in the future? Won’t it just be all automation? While automation certainly plays an increasingly important role in modern industrial facilities, the robot takeover has been greatly exaggerated.
Sure, some low-skill positions have been eliminated by the use of robots and other automated technologies, but there are still hundreds of thousands of open manufacturing jobs that employers are having a hard time filling. Moreover, the more automation there is, the more highly-skilled workers are needed to operate, maintain, troubleshoot, and repair that equipment.
As Jessica Lin notes in a Forbes article, “we have 30 to 50 years until we reach a world of full automation. It’s very hard to replicate the flexibility, speed and dexterity of a person. That’s why Amazon has a lot of robots, but still hired more than 425,000 people this year.”
People remain key assets today more than ever. Because of their importance, employers are now leveraging smart technologies in the form of wearables designed to protect and improve the everyday work experience for employees.
How Can Wearables Improve Safety in the Workplace?
Workplace safety: it’s an issue so fundamental that we tend to overlook its importance when we focus on seemingly bigger issues, such as improving efficiency and productivity via advanced automation technologies. However, employers would be wise to engage their employees in keeping safety first and foremost in their minds.
After all, workplace injuries greatly affect the bottom line. In her article, Lin highlights the impact felt by businesses as a result of work-related injuries:
“Every year in the U.S., nearly three million workers are injured on the job. The most frequent injury across this workforce are musculoskeletal injuries, which are often caused from cumulative wear and tear of the body, along with improper body mechanics. Musculoskeletal injuries are on average the longest injury to recover from, and usually the most debilitating in the long term. These injuries have huge financial implications – $170 billion was lost on workers’ compensation in 2018, and in an industry with high turnover, this means companies are spending unnecessary time and money to replace and retain employees.”
As Pat Stoik advises in an Industry Today article, “Employees are the best and first line of defense against safety incidents, which always disrupt business in some way…A well-executed safety culture not only ensures employees’ well-being, but also prevents disruptions and delays, saving companies money.”
How can companies accomplish this? One answer for food and beverage giant PepsiCo is the use of wearables. As Max Garland points out in a Food Dive article, “Frito-Lay’s need to fill 5,000 positions across its U.S. manufacturing sites to meet heightened demand has underscored the importance of keeping frontline employees healthy and able to work. Using wearables is one way to do that.”
According to Garland, “Thousands of workers at 34 Frito-Lay manufacturing and distribution centers cut back on improper lifting and posture when using Kinetic’s Reflex wearable device… [that] recognizes improper moving and lifting techniques and alerts the user with a vibration.”
In her article, Lin notes that Kinetic is “a New York-based company building wearable technology to reduce workplace injuries for industrial workers: everyone from last mile delivery drivers (who make up 40% of Kinetic wearers) to shipping, construction, manufacturing, and logistics operators.”
To date, companies using Kinetic’s wearables have experienced great success. As Garland notes, “[d]ata from the devices allowed management at Frito-Lay’s Kern Plant in California to determine what areas of the facility frequently featured improper movements…[and] to retrofit equipment and modify workspaces to reduce worker risk…reducing strain and sprain injuries by 19% YoY.”
Lin adds, “Since launching in 2014, Kinetic can now be found on tens of thousands of workers across the country, and customers include Pepsi, Iron Mountain, among others. On average, Kinetic reduces injury rates by 54%, lowers lost work days by 88%, and enables managers the insights necessary to create a safer working environment.”
Kinetic is not the only company producing wearable devices for the workplace. Many other companies have developed wearables that can improve worker safety in a variety of ways. For example, in a JourneyApps Blog article, author Leon van Heerden notes, “Wearables can now tell you which surfaces are too hot to touch, when machinery is malfunctioning, or even when conditional hazards, like spilled fluids, are present.”
Moreover, he points out that wearables can also “warn workers, and their management, when someone is physically overworking themselves and that they need to take a break before they become fatigued and make a mistake that can lead to an injury.” Importantly, improved safety isn’t the only significant impact wearables are making in the industrial workplace.
How Can Wearables Increase Productivity in Industry?
Reducing injuries and time away from the job positively impacts the bottom line, but businesses that have adopted wearables in the workplace have also learned how to use them to increase efficiency and drive greater productivity.
For example, van Heerden writes, “There are many use cases where businesses can improve efficiency: technicians can be connected to vital information about the equipment they are servicing; field workers can be given access to information on inspections; employees can be tracked in challenging environments.”
He adds, “Workers in the field, factory, or warehouse can now access information through wearables, often replacing a touch interface with one that is voice-driven, allowing their hands to remain free for the job at hand.”
Another area in which wearables can make a huge impact is employee training. General Motors uses Google’s Glass to train new hires — hands-free and on-the-go — on an active production line. Alternatively, wearables can also be used for both “immersive task simulations” and “three-dimensional training on how various products work through the help of HMTs and assisted reality,” according to van Heerden.
Will the trend of wearables in the industrial workplace continue? Authors like van Heerden believe it will: “Wearable technology will continue to grow within the industrial sector as it has clearly demonstrated its benefits. Productivity is increased, safety is improved, errors are reduced and training is more meaningful when wearable technology is incorporated.”
Recent research supports his view. Gartner predicts “total wearable sales of $81.5 billion in 2021, while a report by Research and Markets predicts the industrial wearable devices market will exceed $2.78 billion by 2024, increasing annually at a rate of 9.2%.” The same appears to hold true for the logistics industry: “a 2018 study logistics association MHI predicted that within five years, 70 percent of warehousing and distribution facilities would adopt wearables.”
Industry would not be seeing these benefits without the cooperation of willing employees. In his article, Garland notes that employees have readily embraced the use of wearables in the workplace, because “it empowers them to talk with management about how a facility could be improved.” As their behavior in the workplace changes in response to data gathered from wearables, employees can initiate conversations that lead to meaningful changes that improve their jobs.
Contact SACA to Learn More about Smart Automation Certifications
Wearables are just one of the many forms of new advanced, “connected” technologies that characterize what’s commonly known as Industry 4.0. These technologies, as a group, also go by a variety of monikers, including Smart Factory and the Industrial Internet of Things (IIoT).
Today’s workers need more advanced technical and technological skills than ever before. Unfortunately, there aren’t enough workers with these skills to fill the many roles available today, creating what is known throughout industry as the “skills gap.”
How can modern businesses find the workers they need? How will educational institutions teach the skills modern industry needs? These are questions that demand answers, and one promising solution is the development of industry-standard certifications that focus on connected-systems skills. The Smart Automation Certification Alliance (SACA) sits at the forefront of the effort to certify students and workers who demonstrate the required knowledge and hands-on smart automation skills employers so desperately need. To learn more about Industry 4.0 certifications and how SACA can help both educational institutions and industry employers begin the task of bridging the Industry 4.0 skills gap, contact SACA for more information.
- Published in News
Does Smart Automation Eliminate Employment Opportunities In Food & Beverage Manufacturing?
Spoiler alert – no! Contrary to the narrative that evil job-killing robots are coming to limit employment in the manufacturing industry, automation and smart innovations are facilitating: growth, efficiency improvements and well-paying jobs. While it’s true that some plants are struggling to employ enough new workers, the solution to the skills-gap is training. Food and beverage manufacturing environments can be challenging for humans – sometimes featuring extreme temperatures! Interviewed by Food Engineering Mag (.com), David Ziskind, director of engineering at Black and Veatch stated “Focusing on automation in areas where humans are less comfortable is a good place to start”. While automation is leading companies forward, the industry still relies on people. Recent events have put a strain on workers, talking about the fluctuations in customer demands at the beginning of 2020, Fooddive.com tells us, “[…] workers had to simultaneously deal with supply shortages, rapid onboarding of new suppliers, wild demand swings, and fundamental changes in packaging to cater to the shift from foodservice to retail. This happened as stringent new workplace safety rules and remote working caused production labor costs in the U.S. to surge by up to 20%.”
Have You Tried Turning It Off And On Again?
The rapid embracing of industry 4.0 technology in the wake of the COVID-19 is part of, what the World Economic Forum recently coined ‘Great Reset’. This term is often misconstrued by conspiratorial minds, but in reality describes the 4th industrial revolution – ‘a decisive set of actions oriented toward delivering value not only to companies themselves but also to society as a whole’. Technological advancements that have been waiting in the background for more companies to embrace them are now being proliferated throughout industries. People returning to the workforce may find themselves in a complexly modernized environment. This article from Mckinsey.com is optimistic about the reset, ‘by transforming the nature of work through intentional upskilling and/or reskilling efforts, […the great reset is…] empowering workers to realize their potential through new ways of working.’
A Brave New World in Manufacturing
Tyson foods are seeing a major discrepancy between demand for their product and their ability to staff their processing lines adequately, according to a Fooddive.com article Tyson are finding it ‘challenging […] to see the kind of applicant flow necessary to fill the gaps’. The COVID-19 pandemic has led some potential employees to ponder their cost benefit analysis when going to work in areas such as manufacturing, but those personnel could find new opportunities within their existing workplace to acquire more skills, and level-up their employment. New positions have opened up in manufacturing such as:
- Technician
- Support Engineer
- Applications/Software Engineer
- Software Developer
- Service Specialist
All these positions require specialist training and candidates with certification in these areas will be sought out by firms that have embraced industry 4.0. According to this recent Mckinsey study, ‘In Europe and the United States, […] demand for physical and manual skills in repeatable and predictable tasks is expected to decline by nearly 30 percent over the next decade, while demand for basic literacy and numeracy skills would fall by almost 20 percent. In contrast, the demand for technological skills (both coding and especially interacting with technology) is expected to rise by more than 50 percent, and the need for complex cognitive skills is set to increase by one-third.’ Writing for Industry Week.com, the author of Saving American Manufacturing, Michael Collins states, ‘the only viable alternative […for modern manufacturing staffing…] is to focus on investing in advanced training needed for these highly skilled jobs’. And once those skills are in place credentials will be required to properly fill positions within companies.
How SACA can help
Many certifications are available today that address isolated competencies, from machining to maintenance and IT, but SACA certifications are different. They certify “connected systems” skills that address the integration of these technologies with Industry 4.0 technology.
With the help our partners, SACA has created certifications that are industry-driven, developed for industry by industry. They are developed through a rigorous process that begins with the creation of truly international skill standards, endorsed by leading experts in Industry 4.0 technologies throughout the world.
SACA’s Smart Automation certifications use a modular structure to enable them to fit a wide range of individual needs, industries, and educational environments, and are available in three categories – Associate, Specialist, and Professional. Each certification is stackable, allowing individuals to start with one certification and add other certifications to customize their documented skills.
All SACA certifications are occupationally focused, so they prepare individuals for specific careers in the world of Industry 4.0. If you would like more information into SACA’s world-class Smart Certifications, please contact us!
Students that display a flair for lateral thinking will relish roles that involve responding to the automated diagnosis of problems with system components diagnosing problems or inefficiencies in a digital supply network. Maintenance of the processes and components used in an industry 4.0 optimized facilities requires keen critical thinking skills and a deft hand for troubleshooting issues. In addition these skills are valuable to system designers looking to ensure the safest and most efficient product delivery.
Thanks to the help of our partners, SACA has created certifications that are industry-driven, developed for industry by industry. They are developed through a rigorous process that begins with the creation of truly international skill standards, endorsed by leading experts in Industry 4.0 technologies throughout the world.
SACA’s Smart Automation certifications use a modular structure to enable them to fit a wide range of individual needs, industries, and educational environments, and are available in three categories – Associate, Specialist, and Professional. Each certification is stackable, allowing individuals to start with one certification and add other certifications to customize their documented skills.
All SACA certifications are occupationally focused, so they prepare individuals for specific careers in the world of Industry 4.0. If you would like more information into SACA’s world-class Smart Certifications, please contact us!
- Published in News
Transposing your student’s skills into the Smart Factory environment
The industrial sector is currently moving through a paradigmatic shift, as manufacturing companies embrace more automation in the development of smart factories. Industry 4.0 is our present, and future as the most nimble companies poise to become intelligently networked leaders of their field. According to Forbes manufacturers plan to build 40% more smart factories over the next five years, which a Deloite study claims has the potential to create a huge amount of high-skilled occupations. In spite of concerns over potential human redundancies, the progression into the future is creating the need for highly skilled (and well paid) employees. As the industry embraces automation it encourages more opportunity for the development of new expertise, and for existing technical skills to flourish!
Identifying How Your students’ Skills Can Be Integrated Into Industry 4.0
Educators can thoughtfully guide their students into roles that value education and skills when the core principles of how the manufacturing industry has progressed, in response to industry 4.0, are understood. Strategically, mentors hugely benefit from open communication channels, and partnerships with transitioning facilities to identify prevalent needs and design programs that prepare students for success. Additionally, educators should identify which certifications are most recognized by employers.
Enhancing The Role Of IT
Inter-connected manufacturing environments have created the requirement for expertise in: programming, networking, security, and advanced skills in networked systems. For example; IT specialist skills take on a reinvigorated essentiality as smart factories connect their physical systems, operational information, & human assets to control manufacturing, maintenance, inventory, & supply chain operations. Rather than the traditional assumption that IT professionals will see most of their time spent within an office, talent recruited into a smart factory paradigm find themselves integrated across many more departments in a company, trading pocket protectors for hard hats. Smart factories are opening up an entire new range of opportunities for job-seeking IT professionals with the required skills and credentials.
Talk The Talk
Smart manufacturing is being discussed everywhere, from the shop floor to the national media. New technologies in smart factories present the opportunity to work more effectively across disciplines and organizations. An effective modern workforce operating with an automated product chain encourages interdisciplinary collaboration by teams of category experts. Ensure that your students have the credentials that will enable them to walk the walk.
How Will You Manage?
Where issues arise in regards to safety and logistics students can use aptitude for management and planning to optimize an automated work setting. Since a smart factory is designed to be more intelligent and flexible, approaches to the management of people and machines have changed. Organization is no longer performed on a per process basis, say’s Cleverism.com; instead, entire production chains are networked with each other.
Troubleshooting From The Hip
Students that display a flair for lateral thinking will relish roles that involve responding to the automated diagnosis of problems with system components diagnosing problems or inefficiencies in a digital supply network. Maintenance of the processes and components used in an industry 4.0 optimized facilities requires keen critical thinking skills and a deft hand for troubleshooting issues. In addition these skills are valuable to system designers looking to ensure the safest and most efficient product delivery.
A Vast Collator Of Data
The Industrial Internet of Things (IIoT) presents a groundbreaking opportunity for data capture at each step of a manufacturing process. Components of a smart factory can track all elements of the production chain and communicate information and even anticipations within the network. The communication between each device allows unprecedented access to data. Students should understand the complexities of an industrial network.
Moving With The Technology
As the machines on the production line become enriched, so to do the skills of the employees. The sophistication inherent in smart factories encourages, and indeed requires, high-skilled employees. By using the right tautological tools, along with corporate partnerships and accredited certification’s; educators can confidently encourage students, as they develop their proficiency, that they are developing vital abilities for the future. This represents a broadening of the field; and speaks to the in-demand skills that employers are eager to welcome into their companies.
With all of these future careers on the horizon, industry-endorsed Industry 4.0 certifications will become even more valuable. That’s why the Smart Automation Certification Alliance (SACA), a non-profit organization, has made it our mission to develop and deploy Smart Certifications for a wide range of industries.
Thanks to the help of our partners, SACA has created certifications that are industry-driven, developed for industry by industry. They are developed through a rigorous process that begins with the creation of truly international skill standards, endorsed by leading experts in Industry 4.0 technologies throughout the world.
SACA’s Smart Automation certifications use a modular structure to enable them to fit a wide range of individual needs, industries, and educational environments, and are available in three categories – Associate, Specialist, and Professional. Each certification is stackable, allowing individuals to start with one certification and add other certifications to customize their documented skills.
All SACA certifications are occupationally focused, so they prepare individuals for specific careers in the world of Industry 4.0. If you would like more information into SACA’s world-class Smart Certifications, please contact us!
- Published in News
SACA Certifications: Industry’s Missing Link to Solve the Skills Gap
It’s no secret that industries of all kinds are battling a serious supply and demand issue. Due to advancing technology and increasing use of automation, employers need more highly-skilled workers than ever before.
Unfortunately, the supply of workers with the advanced technical and technological skills employers need isn’t keeping pace. This well-known problem is known as the “skills gap.” It’s been a problem for a while now, and experts believe it will only get worse in the near future.
What employers need are workers with advanced “connected systems” skills that will help them operate, maintain, troubleshoot, and repair the automation equipment becoming commonplace in facilities that have adopted new Industry 4.0 technologies.
To date, however, industry and educators alike have been missing the key to solve this skills gap: a set of industry-defined and industry-validated standards that clearly define the skills workers will need to succeed in the jobs of the present and future.
Providing that missing link was the guiding vision behind the creation of the Smart Automation Certification Alliance (SACA). In a recent webinar (“SACA Webinar”) hosted by Matt Kirchner, President of Lab Midwest, representatives of several major manufacturers spoke about their role in the development of SACA’s Industry 4.0 skill standards, as well as how those standards are now guiding their training and education efforts.
SACA’s Vision for Industry 4.0 Certifications
Why are SACA’s Industry 4.0 certifications so valuable? They speak to the in-demand skills that employers across the country — and across the globe — need so desperately.
Not only do the nation’s educational institutions need to build a pipeline of skilled talent to supply employers with the highly-skilled workers they need now and in the future, but incumbent workers also need training to learn the new skills they need to work with the advanced Industry 4.0 automation systems taking over modern manufacturing facilities.
But what are those skills? That’s the key question, and answering that question is what brought SACA into existence. According to SACA’s Executive Director, Jim Wall:
“SACA’s vision from the beginning was to develop a system that’s based upon industry-developed, industry-validated standards that truly define the competencies, performance indicators, and knowledge indicators that are required of individuals to succeed in the world of Industry 4.0.”
To turn that vision into reality, SACA relied upon a wide variety of companies, educational institutions, and organizations to develop, review, and test SACA certification standards. Experts from well-known industry leaders, such as Rockwell Automation, FANUC, Ashley Furniture, Kohler, Foxconn, Boeing, and Hershey, were instrumental in making sure SACA’s Industry 4.0 certifications reflect the competencies that industry needs.
Industry 4.0 is Here to Stay
Several of the industry representatives who shared stories during the SACA Webinar spoke about the changes that Industry 4.0 technologies have wrought and how their companies have been forced to respond.
Al Doty, Advanced Manufacturing Chief Engineer for Harley-Davidson, Inc., revealed that automation has been key to his company maintaining a competitive edge. Not only do new technologies improve efficiency and reduce costs, but Doty noted that employees also expect the company to adopt and use the best technologies available, so that they can perform their jobs more effectively and maintain a positive work-life balance.
Specific new technologies being adopted include advanced robotics and digital twins, according to Scott Theune, President of Plexus. Digital twins are realtime digital counterparts that allow workers to troubleshoot equipment virtually.
In addition to improving efficiency, these new technologies also play a critical role in making manufacturing facilities safer. Improved safety has been a big benefit as industry growth and the skills gap has spurred the need for more automation, noted Andrew Martin, Senior Director of Manufacturing for Generac.
Leaders throughout industry agree: Industry 4.0 is here to stay. According to Michael DeBroux, Senior Mechanical & Automation Engineer and Engineering Supervisor of Greenheck Fan Corporation, “We need to make sure that we are getting personnel and new talent into our company that speaks modern manufacturing languages and is familiar with Industry 4.0 fundamentals.”
OT and IT are Converging in Industry 4.0
According to an i-SCOOP article, “It’s impossible to talk about the evolutions in manufacturing, industrial transformation and Industry 4.0, innovations in areas such as Industrial IoT without mentioning the convergence of IT and OT.”
Historically, operational technology (OT) has referred to “a category of computing and communication systems to manage, monitor and control industrial operations with a focus on the physical devices and processes they use.”
Information technology (IT), on the other hand, “is about business and enterprise systems that store, process and deliver information.” Because Industry 4.0 technologies are becoming more and more commonplace throughout traditional OT equipment, cybersecurity becomes more critical every year.
According to Jim Molter, IT Manager – Smart Factory Deployment of Kohler Co., “Industry 4.0 is forcing us to break down those silos and start to learn to work together…that’s where we’re headed. There’s not going to be a distinction [between OT and IT] anymore.”
Educational Institutions Play a Key Role in Preparing Industry 4.0 Workers
When experts evaluate strategies for bridging the skills gap, it’s clear that educational institutions must play a key role in preparing students for Industry 4.0 careers. But can they do it alone?
The answer is no. Educational institutions must partner with industry counterparts to ensure that the knowledge and skills they’re teaching will produce students with the valuable skills that industries around the country need.
Anne Troka, Community Engagement Manager for Sargento Foods Incorporated, explains a successful approach she helped to develop called Manufacturing 4.0:
“We started conversations with…four schools and four businesses [to] build a partnership to help students — our future workforce — connect with our businesses to really get skills that we need and skills that the students will need…to make them employable in a variety of different careers, because Manufacturing 4.0 is in manufacturing as well as many other industries.”
To date, the partnership has helped to design and build five courses to prepare students for Industry 4.0 careers, including subject areas like mechatronics, industrial controls, robotics, and the Internet of Things. Eventually, students will also be able to earn SACA certifications related to their coursework. In this way, “we’re really connecting education to [career] success,” concludes Troka.
Industry 4.0 Also Requires Upskilling Current Employees
Unfortunately, employers can’t wait for the next generation of highly-skilled workers to emerge from high school or college. As Anthony Ebio, Director of Industry 4.0 Learning for Ashley Furniture Industries, Inc., noted, schools simply aren’t “cranking out the learning and the students fast enough.”
That’s why Ashley Furniture has invested heavily in upskilling its current employees so that they have the advanced skills they need to work with new Industry 4.0 technologies. Ebio noted that they used SACA certifications as a guide when setting up training for incumbent workers: “We found ourselves leveraging a lot of the SACA structure to make sure that we have [curriculum] to support Industry 4.0.”
Other companies are following suit. Ken Evans, Associate Maintenance Manager for S.C. Johnson & Son, Inc., noted that S.C. Johnson has partnered with Gateway Technical College to upskill its employees with an eye toward achieving SACA certifications.
So far both young and older employees have been excited about the prospect of learning and gaining new skills. Plus, using SACA certifications as a guide has allowed current employees to see a payoff for their hard work quickly. According to Evans, “under SACA, [current employees] can get incremental steps of recognition and be proud of it, and we’re proud of them.”
SACA Brings It All Together
If the current skills gap plaguing industries across the world is to be bridged, strategic partnerships between industry and educational institutions must be forged. Schools must begin to produce a pipeline of highly-skilled workers ready to work in an Industry 4.0 environment.
Likewise, industry must upskill its current workforce with the advanced skills needed to operate, maintain, troubleshoot, and repair the Industry 4.0 automation technologies taking over the factory floor.
According to Michael Cook, Director of Global Academic Partnerships for Platinum SACA Sponsor Rockwell Automation, Inc., “no one company can really do this alone…SACA is providing significant leadership here…ensuring that there’s a close fidelity between the academic space as well as what we find relevant in industry. That alignment is a significant part of what SACA brings.”
To learn more about Industry 4.0 certifications and how SACA can help both educational institutions and industry employers begin the task of bridging the Industry 4.0 skills gap, visit the SACA website and then contact SACA for more information.
- Published in News
Can Smart Manufacturing Transform the Food Industry?
What types of products do you buy online? Today, the answer to that question for many people is just about anything and everything. Things haven’t always been that way, though.
In the earliest days of e-commerce, consumers got their feet wet in the online marketplace purchasing products that were known quantities that could be shipped safely and cheaply. More personal items, such as clothing and shoes, retained a foothold in brick-and-mortar stores where customers could try things on to ensure a good fit.
Fast forward to today and it’s easy to see how drastically e-commerce has changed the retail landscape. Some people now purchase all of their goods exclusively online. There are still certain areas, though, where e-commerce has been slow to gain traction. For example, the food industry has yet to replace a trip to the grocery store with an online experience…until recently.
The COVID-19 pandemic changed much about how we live our lives, including that once-simple trip to the grocery store. Now, more and more people are doing their grocery shopping online or via a smartphone app and having their groceries delivered directly to their car at the store.
As a result, the food industry finds itself in need of a transformation to respond to changing realities driven by consumer demand. Experts believe that transformation will come through a variety of new smart manufacturing technologies.
Consumer Demand Driving Changes
When the COVID-19 pandemic began in early 2020, no one fully understood the ways in which our lives would change over the course of the coming months. Routine, everyday tasks, such as shopping for groceries, were suddenly fraught with the potential for exposure to the deadly virus.
Retail grocers were faced with simultaneously managing intense supply chain disruptions that left many shelves bare and customers who wanted as little contact with other shoppers as possible. The solution for many was to pair online shopping (often via an app) with curbside delivery.
Shopping for food online was a new experience for most customers. It didn’t take long, however, for most people to figure out that they could compare prices across various stores just like they would for any other online purchase.
The effect of these changes on the food industry has been significant. As author Katy Askew notes in a recent FoodNavigator article, the food industry is being forced “to rapidly adapt their processes and products to keep up with changing markets” resulting from “elevated consumer expectations.”
Smart Manufacturing to the Rescue
How can food and beverage companies keep up with these rapid changes? Askew spoke with Andrew Smith, Regional Segment Leader – Process & Packaging OEMs at Rockwell Automation, which recently became a Platinum Member of the Smart Automation Certification Alliance (SACA).
According to Smith, “To remain competitive, food and beverage manufacturing systems must optimize productivity and perform at the highest standard. This requires comprehensive and continuous operations improvement.” Increasingly, the food industry is turning to smart manufacturing to achieve those goals.
Smith believes in the potential of smart manufacturing:
“Connected, information-enabled manufacturing – or smart manufacturing – can make all the difference. New technologies are helping food and beverage manufacturers better understand and use their food processing operations. Smart manufacturing can help improve asset utilization, increase yield, drive workforce productivity, optimize resource management, and mitigate security risks.”
Not convinced yet? Smith points to Hillshire Brands as a prime example of what smart manufacturing can do. After the company began using a manufacturing intelligence system at a Texas plant, “the food manufacturer reduced inedible product and waste goals to 0.8% – saving about 5.5 million corn dogs per year.”
Technologies Changing the Game
The impact of smart technologies is not lost on the average person today. Whether it’s the smartphone in your hand or the smart thermostat keeping your home the perfect temperature, nearly every aspect of life has been impacted by advances in technology
Modern manufacturers are no exception, including food and beverage companies. According to Smith, “New developments in technology are redefining food and beverage manufacturing. By combining the Internet of Things, wireless and mobile technologies, data analytics, and network infrastructure, companies can access and act on the data from their operations before a potential problem arises.”
Askew notes in her article that Smith identified five advanced technologies he believes will drive greater adoption of smart manufacturing technologies in the food industry:
Flexible Manufacturing
Flexible manufacturing focuses on how quickly a company can adapt to change. As Matt Graves and Rachel Wilson explain in an article on the Rockwell Automation blog, “It’s about creating a seamless flow from need to delivery. True flexibility empowers manufacturers to stay in tune with their market, by replacing rigid and static operating models with levels of control and responsiveness never previously thought possible.”
When it comes to integrating new technologies, though, the authors stress that companies must not forget about the people using those technologies:
“When it comes to embracing Industry 4.0, integration between departments is key. While new technology can bring data and systems together, getting your people to communicate/collaborate is just as important – and absolutely essential if you want to gain the maximum return on investment.”
Augmented Reality
As Askew notes in her article, “Augmented reality (AR) is a technology that allows users to view and interact with real-world environments through computer generated superimposed images. It enables workers to perform better and avoid safety and compliance risks by providing easy access to the information they need online.”
In smart manufacturing, companies use AR to help technicians troubleshoot problems in real time. For example, maintenance personnel can use an AR app on a smartphone or tablet to zero in on exactly what component of a machine may be malfunctioning and develop a solution more quickly, thereby reducing equipment downtime.
Predictive Maintenance
The heart of smart manufacturing is the collection, processing, analysis, and application of the tremendous amounts of data (sometimes called “big data”) generated by the production process. According to Askew, companies will use “powerful machine learning algorithms and predictive analytics software to offer predictive and prescriptive maintenance.”
Practically, this means that machines equipped with smart sensors can monitor their own performance. Technicians will receive alerts from machines when maintenance needs are imminent, allowing them to maintain and repair equipment before breakdowns occur, thereby reducing downtime and increasing productivity.
Edge Computing
A Rockwell Automation article explains edge computing in this way:
“Edge computing combines a machine’s control and computing hardware into one platform, either with a controller that has a built-in computer or with a computing module that sits on the same rack as the controller. With this two-in-one approach, you can put all your machine’s digital content — such as custom code, the controller’s human-machine interface (HMI) application and any third-party software programs — right where the controller resides, rather than in another location. This creates inherent benefits for end users, including space savings and access to data right at its source. But it also creates new opportunities for you to build entirely new solutions for production applications.”
According to Askew, “Edge computing will complement existing cloud infrastructure by enabling real-time data processing where work is done (for example, motors, pumps, generators, or other sensors). Implementing integrated analytics from the edge to the cloud will help these companies maximize the value of investments in digital systems.”
Digital Twin/Digital Thread
In addition to augmented reality apps, companies are also using advanced digital tools to assist with troubleshooting, such as digital twins and the Digital Thread. According to Askew, a digital twin is “the collection of data created in software representing a real-life system. Machines, controllers, processes, workflow, and any other aspect of a system can be represented digitally, without any interruption to ongoing activities.”
Similar to a digital twin, the Digital Thread “creates a virtual representation of how data travels within a company. The Digital Thread enables supervisory enhancements throughout the supply chain, including delivery of work instructions to operators, quality control sampling, and automated activation of components and materials from vendors, suppliers, and partners”
What can these technologies do for the food industry? Askew paints an interesting view of a future that’s probably a lot closer than we think:
“In the near future, we will see that by interconnecting business systems through the Digital Thread, companies will practically start up new production lines. Using the digital twins, manufacturers will run machines virtually before parts are ordered, discover control issues before support personnel review them, predict future performance challenges and opportunities, simulate line changes to stay keep up with changing customer demands, and will train new staff in non-stop systems of activity.”
SACA Certifications Validate Industry 4.0 Skills
Employees in the food and beverage industry would do well to complement their current skillset with advanced Industry 4.0 skills that will help them change and grow with advances in technology. For those workers wanting to specialize in Industry 4.0 technologies, the certifications offered by the Smart Automation Certification Alliance are a great place to start. SACA offers industry-standard certifications that focus on “connected systems” skills. To learn more about the different types of SACA certifications, visit SACA online.
- Published in News
Helpful tips on how to build a smart automation résumé
To view a multimedia version of ‘Helpful tips on how to build a smart automation résumé‘, please click here.
New year, new you – right?
With the end of 2020 approaching quickly, many are circling Jan. 1, 2021 as an opportunity to improve their happiness and wellbeing. For some, that signals a career change – a way to improve on their daily professional grind.
While COVID-19 has made the job market volatile, there are still careers out there with jobs waiting for people to apply for them. And some of those jobs happen to fall into a sector known as Smart Automation.
What is Smart Automation?
While some know the term as “smart automation”, it goes by many different monikers: the Industrial Internet of Things (IIoT), Industry 4.0, Smart Factory, and many more.
Essentially, smart automation is the use of machines, control systems, and information technologies to optimize productivity and improve efficiency in the production of goods and delivery of services. From building automobiles to sewing buttons on a shirt, it is used all around the world to improve the speed and quality of manufacturing. However, what makes the automation “smart” is a lot like the same idea used when describing smartphones: we are connecting to the Internet of Things (IoT), which allows devices to communicate with other devices via the Internet.
This has ushered in a brand new way of manufacturing, which many are viewing as the Fourth Industrial Revolution – which explains the name Industry 4.0. Smart automation holds the potential for a massive impact on industrial efficiency and proficiency. By combining cyber-physical systems, automation, and the Internet of Things, companies can begin to create a smart factory environment, which could include a team of robots communicating with each other (and human workers) to report on a wide variety of information, such as cycle times, mechanical breakdowns, predictive maintenance, and more.
Why should I be interested in a career in Smart Automation?
While the real boost behind smart automation involves robots and self-driving vehicles, it does not leave human workers out in the cold. As an increase in usage of robots happens, low-skill assembly line-type jobs will begin to fade out, making ways for new careers that have never existed before.
The demand for these highly-skilled workers that can program, analyze, and maintain many parts of these complex systems is so tremendous that companies are having difficulty finding candidates to accept these careers in manufacturing, which has led to a sector-wide hiring struggle, known as the Skills Gap. This means these jobs – many of which are high-paying – are going unfilled due to the lack of qualified workers.
But smart automation doesn’t just live on an assembly line floor. In fact, thanks to the use of smart sensors, smart devices, and other new cutting-edge technologies, which possess the ability to create an enormous amount of data to be monitored and shared via cloud technology, many of the jobs available today require just as much knowledge on IT and cyber-security as any other typical manufacturing skill.
How do I build a résumé for jobs that don’t exist?
Like most jobs, you don’t pick a career by simply liking its name or title: you pick your career based on the skills that you’re good at, or enjoy doing. So with that in mind, here are four tips on how you can improve your smart automation résumé:
Tip #1: Spotlight on your “smart” skillset
By highlighting your “smart” skills – and highly-coveted personal skills like problem solving, critical thinking, and others – as opposed to a particular job’s title, you will be more adept to finding the ideal job for your skillset.
So when constructing your résumé, put an emphasis on your “smart” skillset that showcases you have the specific knowledge and know-how for the skills they are looking for. According to a recent study by Deloitte, many of the future jobs will revolve around these skills:
Tip #2: Include a focused professional summary statement
When introducing yourself through your résumé’s Professional Summary section, include any pertinent industry-needed skills that were called out in the company’s job listing. (Called “value proposition”, highlighting a collection of skills you can provide curated to a particular business or position makes you a more attractive candidate in the process.)
Be straightforward in explaining your skillset, and what you can offer this specific company. Not only will it showcase your most important attributes as early in the review process as possible, but it will also prove to the company that you took the time to study the job listing, not just submitting résumés blindly without reading.
Also, focus on strong character traits that prove your experience, and back it up with accomplishments. Remember to show, not just tell, examples of how you can improve their bottom line. If warranted, consider a compelling statement that describes your current (or previous) profession, especially if they include the “buzzword” skills a company is specifically looking for.
Tip #3: Don’t overlook your training – it matters!
Whether it’s your first career in industry, or you’re retooling for a future position or promotion, training in smart automation matters. From the bedrock knowledge of automation, to understanding all of the safety protocols around these automated machines, having industry-relevant training is critical for positions like these.
So when compiling your previous academic or professional experience, make sure to list any related classroom experience, as well as specific courses that pertain to the position you’re applying for – remembering to focus on your skillset.
If it applies to you, consider adding any apprenticeships, mentorships, or other non-traditional means of training. Don’t overlook any of your training, no matter how menial you might think it is.
Tip #4: Certifications can make (or break) your job search
Let’s be honest here: if Candidate A and Candidate B both have similar skillsets, experience, and recommendations – but only one of them holds an industry-recognized Industry 4.0 certification – it should be pretty clear who is going to get the first job offer.
Most Industry 4.0 or Smart Certifications can showcase to businesses that you are trained under the standard guidelines established by industry leaders. In fact, most companies will prioritize candidates that hold an official industrial certification from an industry-recognized institute, like SACA, for example.
Since these certifications play such a crucial role in the hiring process, consider upping your training regime to include industry-recognized smart credentials.
Getting involved with Industry 4.0 is a “smart” bet
In summary, it’s simple: Industry 4.0 jobs are aplenty, high-paying, and there for the taking.
But they’re not for everybody. These jobs take a specific skillset that rely heavily upon critical thinking and problem-solving. The challenges, though, should not dissuade someone from pursuing a career in smart automation. Instead, it highlights the pressing need for qualified workers in this field of work, and the unlimited possibilities these positions could bring to a world of “smart” manufacturing.
- Published in News
Top 5 Future Smart Automation Careers in Manufacturing
Oh, how five years can change things.
Turning the clock back all the way to 2015, gasoline had fallen under $3 nationally for the first time in four years, NASA was confirming the presence of water on Mars, and the smash-play Hamilton was the hottest ticket on Earth (you know, back when we could still go to concerts…).
Even manufacturing of those times now feels slightly antiquated. Promises of big data driving efficiency and predictive maintenance technologies, which were introduced on a national scale in 2015, are now commonplace around Smart Factories. Today, more efficient strategies are practiced by companies, leading to a manufacturing boom – another prediction-come-true from 2015.
While we could spend time reminiscing about the “ol’ days”, innovation doesn’t take a break. With more products being created daily than we’ve ever experienced before, it only makes sense for manufacturing to keep focused on improving production for future endeavors.
And it begs the question: where do we see manufacturing five years from now? Based on its history, changes are expected, according to Deloitte. Specifically, they predict several important themes will be reflected in these changes, including:
- Putting Humans in the Loop: Organizations are working harder to keep humans in the loop, such as rethinking work architecture, retraining people, and rearranging the organization to leverage technology. The hope is to not only eliminate routine tasks and cut costs, but create value for the customers (and meaningful work for the employees).
- Expanding Digital and “Soft” Skills: Despite the rise of automation, and technology replacing many mundane tasks, manufacturing requires human workers to ensure that everything runs smoothly. The essential human skills deemed most useful over the next decade include critical thinking, creativity, and people management.
- Leveraging the Digital Toolbox: Manufacturing workers are becoming more reliant upon digital tools, such as collaboration platforms, work-based social media, and instant messaging, to effectively complete their work.
In addition to these themes, Deloitte also anticipates five future skillsets that each manufacturing worker should possess, including being proficient in: Technology / Computer, Emerging Digital Technologies, Programming for Robots / Automation, Working with Tools and Technology, and Critical Thinking.
So how can these themes and skills work in combination to create future jobs?
According to Deloitte:
“As digital transformation and the Fourth Industrial Revolution continue to redefine manufacturing jobs of the future, leaders and workers alike need to embrace a work environment that is expected to blend advanced technology and digital skills with uniquely human skills, to yield the highest level of productivity. Understanding how work might change can help the industry as a whole prepare for a future that promises to be transformative.”
With that transformative future comes a new onslaught of smart careers – many of which have been created as a direct correlation to the ever-changing industry. In this article, we will highlight five of the jobs that Deloitte has tabbed as the most promising future smart automation careers in manufacturing, as well as what that position could potentially look like.
Job #1 – Digital Twin Engineer
SUMMARY: A digital twin engineer creates a virtual representation of both the physical elements, as well as the dynamics of how an IoT-connected product operates and interacts. Simply put, a digital twin engineer makes it possible to virtually see inside any physical asset, system, or structure to optimize design, monitor performance, predict maintenance, and improve the overall experience.
Used throughout a wide range of industries, digital twin engineers rely upon their engineering tooling to integrate necessary digital elements to produce the high-quality product. In addition, they act as a working link between the product twin and the performance twin, which can help enhance collaboration with customers, accelerate innovation, design smarter products, and create new services.
RESPONSIBILITIES: Using 3D software and simulations, a digital twin engineer will create digital twins to measure product performance throughout a variety of conditions. The insights discovered through the data help design new products and business models. Engineers also use machine learning, real-time usage, and performance data to optimize product performance and service.
SKILLS NEEDED: In creating virtual replicas of major industrial products, as well as helping companies predict and respond to customer problems using real-time data analysis, digital twin engineers need to be well-versed in simulations, analytics, and software development. Systems engineering, as well as research and development, are also critical.
Job #2 – Smart Factory Manager
SUMMARY: A smart factory manager is a jack-of-all-trades, so to speak. From production and quality, to IT and cyber responsibilities, a smart factory manager takes on an expanded, and often times unique, role of integrating advanced manufacturing, securing connectivity, and understand data analytics to drive a new level of overall equipment effectiveness, or OEE.
The goal of the smart factory manager is to identify data patterns that can help predict quality issues, as well as direct actions in response to these insights. In addition, they will leverage predictive maintenance analytics to identify issues before they happen, and direct preventative maintenance to address future issues.
RESPONSIBILITIES: A smart factory manager must be able to identify and aid in the addition of advanced technologies that enable self-optimization. They must be able to build a variety of automated manufacturing capabilities, such as robot cutting, 3D printing, and more. Finally, they are responsible for managing the installation, operations, and maintenance of all levels of the smart factory solutions “stack” that delivers continuous connectedness and ensures cybersecurity protocols are followed.
SKILLS NEEDED: Being skilled in applied technology, automation, and connectedness are a must for smart factory managers. In addition, operational excellence, deep learning, and innovation are also key to finding success in the field. Digital prototyping and client management are also plusses.
Job #3 – Robot Teaming Coordinator
SUMMARY: With increased automation comes a larger need for robots. And robots, like any other industrial component, needs to be able to effectively perform its predetermined tasks. As a Robot Teaming Coordinator (RTC), it is their task to oversee robots that interact with humans to enable a human rapport with robots, ensuring optimal human-machine interactions.
Generally, the RTC is responsible for monitoring robot performance, and giving feedback to programmers to perfect robot value. However unlike robot programmers, a robot teaming coordinator are often not experts in programming languages, but should have the knowledge to understand how robots are supposed to behave in work environments.
RESPONSIBILITIES: In addition to observing and evaluating robot performance, an RTC is responsible for sharing its feedback with robot programmers, recommending areas for improvement. They will train human team members to help them work more collaboratively with robots, as well as work in tandem with robot coordinators from other departments to identify opportunities to enhance productivity. Finally, all of those results are delivered against key performance indicators to view overall customer experience, improvements in productivity, and more.
SKILLS NEEDED: An RTC needs to be proficient in robot behavioral analysis by enabling a collaborative human-robot working environment, which applies a mixture of digital, social, and human skills to help humans and robots leverage each other’s strengths and improve productivity. This means a robot teaming coordinator needs to be well-versed in human-machine collaboration, as well as robot management.
Job #4 – Smart Safety Supervisor
SUMMARY: In most workplace environments, safety is the number one concern. That’s no different in a Smart Factory – only this time, it’s the Smart Safety Supervisor who is responsible for overseeing proper safety procedures are being utilized. A Smart Safety Supervisor works with operational, logistics, and technology teams to ensure safety, as well as finding new synergies that can improve the safety of workplaces.
With Smart Factories dealing with autonomous equipment, unmanned drones, and advanced materials, a Smart Safety Supervisor needs to be fluent in advanced technologies, and match those applications – such as smart helmets or augmented reality (AR) glasses to help create a safe and efficient work site. They will also use their broad knowledge of regulations, Environment, Health & Safety (EHS) standards, and available technologies to help companies develop technology implementation road maps, or help leverage the digital twin of a construction site to oversee health and safety of workers and machines.
RESPONSIBILITIES: When it comes to keeping workers safe, a Smart Safety Supervisor has a laundry list of responsibilities. From identifying new technologies to meet set safety targets, to formulating safety procedures and plans to reduce potential safety hazards, a Smart Safety Supervisor will be responsible for taking all of the necessary steps to ensure workplace safety. The job also includes incorporating specialized risk management principles between machines and humans, supervising safety specialists, and acting as a field safety inspector on incident investigations.
SKILLS NEEDED: The most necessary skill is having an advanced working knowledge of construction safety, safety management systems, and occupation and health regulations. Smart Safety Supervisors are skilled in EHS, workplace inspection, and risk assessment, as well as understanding digital tools and technologies to aid in keeping everyone safe. Finally, having experience developing and implementing multiple health and safety programs for various projects is a plus.
Job #5 – Smart QA Manager
SUMMARY: A “smart quality assurance (QA) manager” manages product quality using digital technologies. That means a smart QA manager will oversee an ecosystem of machines and work center sensors, artificial intelligence (AI), and virtual reality (VR) support technologies to proactively detect quality escapes and machine maintenance issues, as well as develop solutions to address those root causes of quality issues.
From developing requirements for AI and machine-learning (ML) algorithms that identify products defects as early as possible, to reducing the number of defects per part produced, the main task of a smart QA manager is to minimizes production downtime, and maximize productivity by reducing manual inspection.
RESPONSIBILITIES: A smart QA manager will be looked upon to work with the facility manager to develop and maintain the production schedule, as well as plotting historical data to develop predictive quality controls and detection algorithms. In addition, they will be responsible for conducting quality issues root cause analysis, providing corrective actions, and identifying new technologies to incorporate into QA systems.
SKILLS NEEDED: An experienced QA manager is trained in leveraging smart technologies to reduce the number of defects per part produced, with goals to enhance overall productivity. Other useful skills include operational excellence, innovation, automation, and digital prototyping. Like all future smart positions, it also requires a passion for deep learning.
Need Help Certifying Your Workforce for Smart Automation? Consider SACA!
With all of these future careers on the horizon, industry-endorsed Industry 4.0 certifications will become even more valuable. That’s why the Smart Automation Certification Alliance (SACA), a non-profit organization, has made it our mission to develop and deploy Smart Certifications for a wide range of industries.
Thanks to the help of our partners, SACA has created certifications that are industry-driven, developed for industry by industry. They are developed through a rigorous process that begins with the creation of truly international skill standards, endorsed by leading experts in Industry 4.0 technologies throughout the world.
SACA’s Smart Automation certifications use a modular structure to enable them to fit a wide range of individual needs, industries, and educational environments, and are available in three categories – Associate, Specialist, and Professional. Each certification is stackable, allowing individuals to start with one certification and add other certifications to customize their documented skills.
All SACA certifications are occupationally focused, so they prepare individuals for specific careers in the world of Industry 4.0. If you would like more information into SACA’s world-class Smart Certifications, please visit our website!
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Industry-Recognized Apprenticeship Programs: IRAPs Promise New Opportunities
LOUISVILLE, KY—OCTOBER 14, 2020
Industries across the United States have been struggling for years to fill open positions with qualified workers. Despite widespread recognition of the problems industries face, the skills gap has continued to widen.
Rather than bringing new solutions, 2020 instead saw a global pandemic make an already-tough jobs situation worse. Due to the COVID-19 crisis, millions of American workers have lost their jobs, many of them permanently.
As the U.S. seeks to recover from “the most devastating economic crisis since the Great Depression,” there is no shortage of problems that must be addressed and solutions that need to be formulated. How effective those solutions are will dictate the speed and scope of economic recovery.
Unlike past economic recovery initiatives that often pushed people toward college degrees, experts believe that our current economic recovery from the COVID-19 Recession must instead focus on practical skill development for jobs industries need. To that end, community colleges and skills training may play a critical role.
Another potential solution with a proven track record of success is apprenticeship. In fact, many believe new industry-recognized apprenticeship programs (IRAPs) will provide fresh opportunities for both American workers and industries that desperately need skilled talent. How? IRAPs will expand the use of the apprenticeship model to industries that haven’t used it or have underutilized it in the past.
What Are IRAPs?
So what exactly are IRAPs anyway? According to the U.S. Department of Labor’s (DOL) Apprenticeship.gov website:
“Industry-Recognized Apprenticeship Programs are high-quality apprenticeship programs recognized as such by a Standards Recognition Entity (SRE) pursuant to the DOL’s standards. These programs provide individuals with opportunities to obtain workplace-relevant knowledge and progressively advancing skills. IRAPs include a paid-work component and an educational component and result in an industry-recognized credential. An IRAP is developed or delivered by entities such as trade and industry groups, corporations, non-profit organizations, educational institutions, unions, and joint labor-management organizations.”
For example, the Smart Automation Certification Alliance (SACA) was recognized as one of 18 initial organizations designated as an SRE by the DOL on September 23, 2020. SACA may now evaluate and recognize IRAPs consistent with DOL standards.
What are those standards? According to the DOL’s IRAP Fact Sheet, high-quality IRAPs must meet the following 10 requirements:
- Paid Work
- Written Training Plan
- Written Apprenticeship Agreement
- Specialized Knowledge and Experience
- Safety
- Equal Employment Opportunity
- Credit for Prior Knowledge
- Mentorship
- Industry-Recognized Credentials
- Disclosure of Costs and Fees.
When Were IRAPs Created?
IRAPs are a relatively-new solution in the area of workforce development. Their history can be traced back to June 15, 2017, when President Trump issued an Executive Order to Expand Apprenticeships in America.
According to a DOL press release, the order established the 20-member Task Force on Apprenticeship Expansion, which was “headed by the Secretary of Labor and co-chaired by the Secretaries of Commerce and Education.”
The DOL’s IRAP Fact Sheet notes that the president’s order “directed the Secretary to consider proposing regulations that promote the development of apprenticeship programs by third parties…especially in sectors where apprenticeship programs are insufficient.”
The Task Force subsequently recommended the establishment of IRAPs in May 2018. Eventually, as the IRAP Fact Sheet notes:
“To address America’s skills gap and to rapidly increase the availability of high-quality apprenticeship programs in sectors where apprenticeship opportunities are not widespread, the [DOL] has issued a Final Rule that establishes a system for advancing the development of high-quality IRAPs.”
IRAPs then became official when new regulations took effect on May 11, 2020.
How Do IRAPs Differ from Traditional Apprenticeships?
According to a recent Forbes article by Ryan Craig:
“For years, policy makers have struggled with the question of how to expand apprenticeships from traditional blue collar building and industrial trades to fast-growing sectors like technology, healthcare, and professional services. On a per capita basis, the U.S. is far behind other nations: Germany has nearly 20x as many apprentices, and the UK has 14x.”
Craig further notes that the goal of IRAPs is:
“to increase the number of actual American apprentices from 500,000 to 5 million by decentralizing apprenticeship authority from the DOL to hundreds of third party IRAP authorizers [SREs]…The expectation is that while DOL registered apprenticeships are infamous for the amount of paperwork required, IRAPs will be much less onerous and therefore more popular.”
Rather than taking apprenticeships in an entirely new direction, IRAPS are “intended to run in tandem with the department’s long-established registered apprenticeship program,” according to an article from the Community College Daily website. Indeed, the DOL’s IRAP FAQ clearly notes:
“IRAPs and RAPs [Registered Apprenticeship Programs] will work on parallel tracks with the support of the Department. The Registered Apprenticeship system has produced successful results in many industries for over 80 years and it will continue to do so. The industry-led, market-driven approach outlined in the IRAP final rule will give employers and other stakeholders the additional flexibility necessary to expand the apprenticeship model into new industries where registered programs are less prevalent and to address the diverse workforce needs of different industries and occupations. IRAPs provide a new apprenticeship pathway that lets industry organizations take the lead in identifying high-quality apprenticeship programs and opportunities based on the needs in their industry.”
Consistent with the goal of expanding the apprenticeship model to new industries, one notable difference between IRAPs and RAPs is that SREs are prohibited from recognizing IRAPs in the construction industry. According to article by Katie Spiker from the National Skills Coalition:
“This carve out was…the subject of a massive campaign by the building trades unions…According to proponents of the construction industry exclusion, and the Department in their justification of excluding construction in the final IRAP rule, the fact that the majority of U.S. apprenticeships are in the construction industry is evidence the model is effective for the industry and that expanding IRAPs to construction is not necessary to meet the goal of expanding apprenticeships in the U.S.”
Who Will Benefit from IRAPs?
The DOL clearly outlines a set of expected benefits to both workers and businesses in its IRAP Fact Sheet. For businesses, the DOL expects IRAPs to:
- provide an additional pathway to assist career seekers and job creators;
- serve the needs of business by expanding apprenticeships across more industries;
- use innovative, industry-driven approaches to scale a proven workforce education model;
- allow more flexibility to design apprenticeship programs that meet business needs; and
- supply an immediate pool of workers for today and skilled talent for tomorrow.
For workers, IRAPs are expected to:
- offer opportunities to earn and learn, while obtaining valuable, portable, industry-recognized, competency-based credentials;
- provide training in standards that are developed by the industry, ensuring an apprentice develops the skillset needed for career success;
- increase the opportunities for apprenticeship programs across all sectors in the economy; and
- provide an alternative to college for finding career success that allows workers to obtain high paying jobs without going into debt.
Katie Spiker echoes the view that both workers and businesses should benefit from IRAPs: “The IRAP initiative is evidence of the need to modernize apprenticeship, expand access to workers to earn industry-recognized credentials and allow businesses to play more of a role in helping tailor the kind of training their workers receive to meet their specific needs.”
While traditional registered apprenticeship programs have been successful for years, Roy Maurer notes in a recent article for SHRM, the Society for Human Resource Management, that “only about 0.2 percent of the U.S. workforce has taken advantage of the programs, primarily in trades and construction.” The DOL believes IRAPs “will effectively expand apprenticeship in telecommunications, health care, cybersecurity and other sectors where it’s currently not widely used.”
Rachel Greszler, senior policy analyst at The Heritage Foundation, believes the benefits to workers are clear:
“The [IRAPs] rule is an important step in opening up more nontraditional and affordable education opportunities that could particularly benefit younger Americans who have been left behind by America’s higher-education system, as well as current workers who have been negatively impacted by changes in industry and technology. It’s not in everyone’s best interest to pursue an expensive four-year college education, and these types of apprenticeships make it possible for individuals to obtain the education they need for a promising career without taking on debt, and instead, actually being paid in the process.”
As U.S. Labor Secretary Eugene Scalia summarized in a DOL press release:
“As workers seek to reenter the workforce following the economic disruption caused by coronavirus, [IRAPs] and the SREs that recognize them will provide new opportunities for Americans to earn a living while learning the skills needed in a changing job market.”
Where Can I Learn More About IRAPs?
According to Ryan Craig:
“There are millions of unemployed workers whose jobs are unlikely to return once the pandemic subsides. So one of the most important policy questions in America today is how they’ll find paths back to work…If there is an answer, apprenticeships will almost certainly play a leading role.”
If you want to learn more about IRAPs and the SREs who will be helping to bring them to life, be sure to check out the DOL’s Apprenticeship.gov website. The latest information and developments will be posted there as IRAPs take shape and begin to fulfill the goal of expanding apprenticeships into new industries while helping workers gain new skills.
- Published in News
SACA: Certifying the Smart Automation Workforce
The evolution of automated technology continues to transform the world’s industrial workplaces in countless ways and there’s no sign of this industrial metamorphosis losing momentum. As Industry 4.0 technology adoption increases, how do companies ensure that potential and current employees have the necessary skills to keep up? Many employers use certifications as a measure of competency, but credentials for Industry 4.0 technology and skills are often tied to specific brands of equipment. But why limit the training spectrum by using a specific brand? How does this make sense when facilities use equipment from multiple brands on their shop floor? What about something more universal, like a certification for job tasks regardless of the equipment used on the manufacturing floor?
The Smart Automation Certification Alliance (SACA), a non-profit organization with the mission to develop and deploy modular Industry 4.0 certifications for a wide range of industries, was founded to aid companies that need employees that are fully versed in cutting-edge Industry 4.0 skills. Working with industry leaders to develop these standards and certifications, SACA built industry-driven credentials with input from companies like FANUC, Rockwell Automation, the Hershey Company, Ashley Furniture Industries, and many others. SACA is also designated as a Standards Recognition Entity (SRE) by the United States Department of Labor.
SACA Certifications: Built for Industry by Industry
Developing the certifications was a rigorous process. Beginning with the creation of truly international skill standards, SACA worked with industry leaders and experts in Industry 4.0 technologies to make a set of credentials that certify an individual’s mastery of advanced manufacturing and Industry 4.0 job tasks. SACA conducts annual reviews for the certifications ensuring that they remain current as technologies and processes continue to evolve at a rapid pace. By focusing on job tasks and the skills required to perform those tasks, SACA’s certifications give employers assurance when they’re hiring new employees, provide proof of competency for those seeking jobs with companies that have adopted Industry 4.0 technologies, and provide schools and colleges with the confidence that they’re teaching relevant skills.
Who Benefits from SACA Certifications?
Whether you’re training individuals to become technicians, IT professionals, automation engineers, or numerous other smart factory-related careers, SACA certifications equip students and employees to become highly successful professionals in Industry 4.0 environments. SACA offers certifications in three stackable categories: Associate, Specialist, & Professional. These certifications use a modular structure that provides flexibility to fit a wide range of individual needs, industries, and educational environments.
Additionally, the Specialist and Professional-level certifications contain stackable micro-credentials that build upon each other to complete comprehensive certifications. For example, an individual can begin earning micro-credentials for electrical systems, pneumatic systems, robotic operations and many more, which would eventually stack up to SACA’S Certified Industry 4.0 Automation Systems Specialist I credential.
Or companies can use individual micro-credentials to verify that their workforce is up-to-date with the latest technologies and skills to close any skill gaps that already exist. With so many choices in micro-credentials, individuals can quickly transform into versatile team members that can help with a variety of smart factory applications.
Because these certifications are modular, schools and industrial training facilities can select the certifications and micro-credentials that best meet the needs in their community or company. In many cases, there’s no need to purchase additional training equipment to prepare for the certifications. Many of the skills and micro-credentials from SACA rely on equipment schools or training centers may already have.
How Can Someone Get a SACA Certification?
To attain SACA certifications, individuals must be employees or students of a SACA member institution. Individuals can prepare for the online examination using any text, online courses, or other means that align with the standards. Individuals passing the written examination receive a Silver Credential. Individuals can also demonstrate hands-on competencies on industrial-grade equipment that they’ll see in the workplace. If someone passes both the written and hands-on examinations, they will receive a SACA Gold-level Credential.
SACA certification examinations and hands-on testing are performed at SACA Authorized Testing Centers. Organizations can become a testing center by becoming a SACA member.
How Do I Become a SACA Member? What Are the Benefits of SACA Membership?
SACA offers membership for both educational institutions and industry, so professionals representing those organizations that are interested in membership can reach out to SACA on SACA.org. Educational memberships for high schools and colleges enable these institutions to become authorized certification centers, deliver free certifications to students, and stay informed about the latest developments in Industry 4.0 technology. Companies get all of the aforementioned benefits of educational memberships with additional incentives unlocked by different levels of industry membership. For instance, companies that are Silver Members and above will have a portion of their membership fee designated for named scholarships to sponsor educational institutions and teachers starting new Industry 4.0 certification programs.
Contact SACA Today to Learn More
Industry 4.0 is here and being rapidly adopted by companies around the globe. If students, employees, and companies aren’t preparing and keeping up with this wave of big data, they’ll get swept away by the competition. SACA can help all of the above to adapt and prepare for success. Fill out a contact form to learn how to join SACA, where to find testing sites, and how to get certifications in the hands of your students and employees.
- Published in News
Macomb Community College Joins SACA to Provide Students with Industry 4.0 Certifications
LOUISVILLE, KY—AUGUST 17, 2020
The Smart Automation Certification Alliance (SACA) is pleased to announce that it has recently entered into an agreement with Macomb Community College and ATS Midwest to support the college’s efforts to align its education and training to meet the realities of Industry 4.0. Students completing Macomb’s advanced manufacturing programs will soon earn SACA certifications, giving them a competitive advantage in today’s job market.
Today’s students face a far different world of advanced manufacturing than existed a decade ago. While automation technologies have been commonplace for many years, the Internet has brought about a convergence of new “connected” technologies that is revolutionizing how products are made.
Known as the Fourth Industrial Revolution or Industry 4.0, this latest disruption of the advanced manufacturing world is resulting in reduced downtime and increased quality, productivity, and overall efficiency in industries of all kinds thanks to advanced technologies that make up what is known as the Industrial Internet of Things (IIoT).
IIoT technologies include such things as advanced robotics, machine learning, artificial intelligence, autonomous vehicles and machines, cloud-based data analysis, and cybersecurity. As companies increase their use of networks and Internet technologies, they are connecting more devices, from smart sensors to smartphones.
As a result, these highly-connected systems require new skills in almost every occupation. To succeed in an Industry 4.0 environment, current workers and today’s students must learn to interact with software, data, networks, and smart devices.
While there are many certifications available today that address isolated competencies, from machining to maintenance and information technology (IT), SACA certifications are different. SACA’s Industry 4.0 certifications certify “connected systems” skills that address the integration of the many types of advanced manufacturing technologies with Industry 4.0 technology.
SACA’s Industry 4.0 certifications have been developed for industry by industry through a rigorous process that began with the creation of truly international skill standards. These standards have been endorsed by leading experts in Industry 4.0 technologies around the world.
Working with forward-thinking institutions like Macomb will enable SACA to accomplish its vision to provide highly-affordable, accessible Industry 4.0 certifications that significantly increase the number of individuals who possess the skills represented by these credentials.
The result will be an increasing number of students prepared to be successful in an Industry 4.0 world, as well as more companies that have the highly-skilled workers they need. Don Hutchison, Macomb’s Dean of Engineering and Advanced Technology, agrees:
In southeast Michigan, industry already needs employees who understand how advanced manufacturing systems integrate. At Macomb, we are listening to industry and creating training for individuals and industry that meets the challenges and opportunities of Industry 4.0. Arming Macomb’s graduates with SACA certification signifies to employers that they are prepared to successfully navigate the complex, integrated nature of today’s manufacturing environment.
Fortunately, Macomb also enjoys the support of local industry. Tom Kelly, Executive Director and CEO of Automation Alley, Michigan’s leading manufacturing and technology business association and Industry 4.0 knowledge center, supports Macomb’s vision:
It is encouraging to see Macomb Community College commit to Industry 4.0 training, which will help to ensure industry receives graduates with employable skills. Today, technology is moving at an accelerated pace which requires a new set of working skills. If our state is to keep pace and maintain a global leadership position in manufacturing, we must transform and continuously develop our talent pipeline.
SACA looks forward to a long relationship with Macomb as they, together with industry partner ATS Midwest, begin a thorough review of all of the college’s advanced manufacturing programs to ensure SACA certification requirements are incorporated into the programs’ core curricula. The parties will also be reaching out to local industry to confirm that SACA certification requirements reflect the skills needed by industry. For more information about SACA and how its Industry 4.0 certifications can prepare your students for the jobs of the future, visit SACA.org or contact SACA Executive Director Jim Wall.
- Published in News
